Product filling system

ABSTRACT

An apparatus and method are disclosed for filling a package having an upwardly extending open mouth to prevent jam-up and breakage of the product. An arcuately shaped rod is moved in a rotary path in the mouth to cause the product to have a positive whirlpool action and induced spiraling in order to seek the best orientation to enter the package. The tip of the rod is positioned along the centerline of the rotary path and the centerline of the package to provide a full sweep within the vortex pattern and allow maximum space for entrance around the package for the spiraling product. Gentle agitation of the product to break up lumps is provided by a tortuous path within the vortex pattern and limited flexure of the rod. The whirlpool action is enhanced and the integrity of the product insured by feeding the product tangentially with respect to the vortex and operating the rod at the same speed as the merging product.

United States Patent Primary Examiner-Charles J. Myhre Att0rney-Lowe and King ABSTRACT: An apparatus and method are disclosed for filling a package having an upwardly extending open mouth to prevent jam-up and breakage of the product. An arcuately shaped rod is moved in a rotary path in the mouth to cause the product to have a positive whirlpool action and induced spiraling in order to seek the best orientation to enter the package. The tip of the rod is positioned along the centerline of the rotary path and the centerline of the package to provide a full sweep within the vortex pattern and allow maximum space for entrance around the package for the spiraling product. Gentle agitation of the product to break up lumps is provided by a tortuous path within the vortex pattern and limited flexure of the rod. The whirlpool action is enhanced and the integrity of the product insured by feeding the product tangentially with respect to the vortex and operating the rod at the same speed as the merging product.

PRODUCT FILLING SYSTEM The present invention relates to an apparatus and method for filling a package and, more particularly, to an improved system for filling a package with loose product by gravity through an upwardly extending mouth.

In a form-and-fill packaging operation, a continuous packaging film is passed over a tubular former for shaping into a continuous tube followed by heat-sealing together the overlapped side edges to form the longitudinal seam and thus complete the tube A first transverse seal is provided along he bottom of the tube to in effect form an elongated package open at the top at the mouth of the former for filling with product. After the product has passed through the mouth and down the tubular package a second transverse seal is made across the tube for confining of that charge of product. Simultaneous with the forming of the second seal the film is cut at the center of said seal whereby a completed package falls away and the bottom seal of the next package is completed. Also, the tube with the partially formed package is moved relative to the former through a distance of one package length and a charge of product is once again fed through the mouth of the package formed by the top of the former to thus begin the next packaging cycle.

in such an arrangement, one of the limiting factors of the speed of the machine is the time for transfer of the product from the scale (in which the product is weighed in charges or batches) down through the mouth of the former and into the bottom of the tubular package. This limitation is particularly acute in the case of packaging light and fragile products, such as potato chips, where the feed of the product soley by gravity is generally too slow for efficient cycling of the packaging machine. This condition has been somewhat alleviated by providing blasts or jetstreams of air for start and assist of the transfer of the charge of product from the weighing hopper, along the feeding chute and through the mouth of the former. In addition to causing more rapid acceleration of the product to speed up the transfer time, the blasts of air have been found to aid in preventing jam-ups of the product along the feed path.

However, even with air blast assist incorporated in the machines there remains a tendency for certain products to jam at the narrowed mouth of the former from time to time. Jamups of the product at this critical area are most often caused by lumping" of the product by sticking together of a sufficient number of chips to form a block, having a single chip with a crosswise dimension greater than the width of the mouth of the former or having a product which due to its lightness tends to float in the area of the mouth and thus becomes slowed whereupon orderly travel is interrupted and wedging of the product across the mouth occurs. Unless relieved or corrected, the jamming of the product at the mouth of the former immediately results in loss of production due to running of dry cycles of the machine resulting from the inability of product to pass downwardly into the package being formed. This occurrence is followed by the overflow of product at the mouth of the former into the machine and the surrounding floor area requiring a substantial amount of cleanup. The requirement that the machine be stopped for the cleanup and manual relieving of the blockage causes an extended downtime for the machine with a resultant serious loss in production.

Prior to the present invention, attempts to overcome the jamming problem have centered around providing a means which is effective to forcibly relieve any jam-ups that occur after each filling operation and prior to completion of the package. Such arrangements have not been satisfactory mainly due to the undesirable breakage of the product in forcing or poking the product through the mouth of the former. Also, the need for delaying the formation of each package until the relieving means has operated and the trapped product has had time to fall to the bottom of the tubular package slows the overall cycling time of the machine and thus reduces the efficiency.

Accordingly, a main object of the present invention is to provide an apparatus and method for correcting the jamming problem in a package filling system without the use of force designed to break the product to relieve the jam-up.

[t is another object of the present invention to provide a system and method for' filling a package through an open mouth with a light and fragile product, such as potato chips, which operates continuously to prevent: jam-ups and thereby reduce the overall cycling time of the packaging operation.

it is still another object of the present invention to provide a filling system wherein the product is stirred as it enters the mouth of the package so as to generate positive whirlpool action and a spiraling of said product for prevention of jam-ups.

Keeping the above object in mind, a brief description of the product filling system and method of the present invention can now be given. Essentially, the product is received from the weighing hopper of the machine by an inclined chute which in turn directs the product to the mouth of the former and the package. lntersecting the flow of the product at the end of the chute is a product stirring means in the form of an arcuately shaped rod which moves in a rotary path to impart a positive whirlpool action to the product; the flow of the product thus assuming a vortex pattern as it is transferred from the inclined chute through the mouth of the former and into the tubular package. With this arrangement the product is kept in constant motion in the critical restricted mouth area so that it passes quickly and smoothly into the package without a possibility of a jam-up occuring. Of particular advantage is the fact that the stirring motion is continuous throughout the flow of the product so that the delivery of the entire charge to the bottom of the tubular package proceeds without delay.

In accordance with the preferred embodiment illustrated for purposesof disclosing the invention, the operative end of the rod extends down into the mouth of the former so that the stirring action is at the point of the greatest tendency for jamups. The whirlpool action is enhanced by positioning the inclined chute relative to the rotary path of the stirring rod so that the product is brought into the mouth area along the tangent to the rotary path. In accordance with a related method aspect of the present invention. the rod. is rotated so that the tangential speed is substantially equal to the linear speed of the product being received from the delivery chute. As a result of these two features, unequal forces on the product at the point of entry into the whirlpool are avoided and breakage of the product is effectively prevented.

In accordance with another feature of the invention, the tip of the operative end of the rod is positioned at the center line of the rotary path so that the product is effectively swept across the full expanse of said path. A is, the tip of the rod is preferably positioned along the centerline of the former so that maximum space around the periphery is allowed for the spiraling product moving outwardly due to centrifugal force once the product is inside the package.

The former, inclined chute and stirring rod form a triangular intersection at the mouth of the former so that the product follows a Z-shaped path during the stirring operation to encourage separation of any product lumps due to the dynamic forces within the vortex. A further feature is concerned with the rod having limited flexure capability along its length so as to provide additional product agitation to the critical area. Also, the outward extent of the rod in the rotary pathfs such as to place said rod in juxtaposition with the forward lall of the funnel or filling tube at the triangular intersection at a position located substantially from the of entry of the product into the vortex pattern. This wall may thus aid in initially guiding the product into engagement with the rotating rod to provide the desired tight spiral for entry into the mouth. The side and rear guidewalls of the filling tube as well as the corresponding walls of the package are spaced from the rotating rod to cause radially outward shifting and turning of the product after completing approximately turn around the vortex thus adding to the dynamic forces preventing jam-ups and product lumping.

Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description, wherein I have shown and described only the preferred embodiment of the invention, simply by way of illustration of the best mode contemplated by me of carrying out my invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modification in various obvious respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.

In the drawings:

FIG. I is a side view of a filling system utilizing the principles of a product stirring rod to cause a jam preventing whirlpool action in accordance with the teachings of the present invention; and

FIG. 2 is a top view of the filling system taken along line 2-2 of FIG. 1 showing the movements of the product through the system from above.

With reference now to FIGS. 1 and 2 of the drawing, the specific details of the preferred embodiment of the invention illustrated will be set forth. Thus, there is provided a product filling system for effecting delivery of a charge of product, such as potato chips C, from any suitable source (not shown), such as a conventional weighing hopper. The potato chips C follow the flow path indicated by the dotted line arrows in FIG. 1 down an inclined chute 11, through a funnel or filling tube 12 and into an upwardly extending mouth 13 presented by a package or packaging tube T. The package T has been formed by passing of a continuous web W up and over a conventional winged former 14 which thus performs the function of presenting the package T with the open mouth 13. As illustrated, the funnel 12 preferably terminates just above mouth 13 of the package T and in line therewith around the full periphery so that the full cross-sectional area of the package T is available to for receiving product. The longitudinal side edges of the web W are secured together and the transverse seals of the finished packages are formed by conventional heat-sealing apparatus well known in the art. As will appear, while the apparatus and method of the present invention are particularly adapted for overcoming problems in product filling systems of form-and-fill machines, as illustrated and just described, it is contemplated that the invention can be practiced in other product filling environments with equally favorable results.

Accordingly, proceeding with a description of the device forming the heart of the present invention, with reference to FIG. 1 there is shown a product stirrer S comprising a downwardly extending rod which passes through the funnel 12; the operative end 20a of said rod 20 being positioned within the mouth 13 of the package T, as defined by the upper lip of the former 14. The rod 20 is carried by a disc 21 so as to be eccentrically positioned with regard to drive shaft 22 of a motor M. The motor M, which can be of any conventional type including electric or fluid turbine, is mounted in the desired position for support of the rod 20 by a bracket 23 fixedly secured to the frame of the machine (not shown): it being understood that such frame also carries the chute 11, the funnel l2 and the former 14 in any conventional manner.

In operation, the rod 20 is rotated by the shaft 22 in the counterclockwise direction, as denoted by the arrow 24 and the dash-dot line midpoint position shown by composite consideration of FIGS. 1 and 2. As the rod 20 0 moves in a rotary path, the product after leaving the inclined chute 11, is entrained by the rod 20 and given a positive whirlpool action as it enters the mouth 13. This whirlpool action thus is operative to keep the chips C in a constant downward spiraling motion through the mouth 13 and prevents them from settling into a blocking position across said mouth 13 much like sediment in a sink is prevented from settling and is more readily accepted in the drain when a vigorous action is present.

As the product spirals through the mouth 13 under the combined influence of gravity and the rotation of the rod 20 of the stirrer S, centrifugal force operates to project the larger chips C toward the outer periphery; the corresponding centripetal force serving to urge the smaller chips C radially inward. Since the larger chips C thus form the outside boundary of the spiral flow path, the narrow gap between the funnel I2 and the mouth 13 is passed without difficulty or loss of product which might otherwise occur with a straight flow arrangement. After the chips C enter the package T the jam preventing spiraling movement is continued toward the bottom of the package T where the final transverse seal completes the packaging operation.

Several important aspects of the product stirrer S can now be examined in detail. First, the rod 20 is preferably arcuately shaped along its length as shown in FIG. I. This preferred shaping of the rod 20 gives an optimum stirring action by the rod 20 since all of the chips C are assured of being influenced by the rod 20 to move in the vortex pattern either by direct engagement, or indirectly as a result of being pushed by'adjacent chips. also, with the tip of the operative end 200 being positioned on centerline or axis 30 of the rotary path, a full sweep of the area in which the chips C might be positioned upon entering the mouth 13 is assured.

The positioning of the tip of the operative end 200 can also be seen to be critical with respect to the former l4 and the package T held thereby. That is, the tip is also positioned along center line 31 of the former 14 so as to allow maximum space around the periphery of the inside of the package T. This gives the spiraling product moving outwardly due to the centrifugal force of the whirlpool action maximumclearance for free movement once inside the package T to insure against possible crushing of the product between the rod 20 and the sides of the package T and/or possible tearing or other damage to the package T as a result of the movement of the rod 20.

To obtain maximum separation of the individual chips C and prevent the propagation of lumps in the product to the mouth 13 where a block could be formed thereby, the former l4 and thus the package T, the inclined chute II and the stirrer S are positioned so as to form a triangular intersection, as shown in FIG. I. This means that as the chips C slide down the chute 11 and leave the end thereof, they are projected into the path of the stirring rod 20 at an angle with respect to the axis 30, as denoted by the dashed line flow arrows. After the stirring rod 20 has moved to the full line position of FIG. I, the chips C are redirected in a combined reverse and downward movement, as denoted by the continuation of the dashed line flow arrows. Finally, still referring to FIG. 1 and the flow arrows, the chips C are directed on the far side of the rotary path back in generally the same direction as they entered the influence of the stirrer S. This Z-shaped or tortuous path positively generated by the rotation of the rod 20 means that sufficient time and distance of vortex movement exists whereby any lumps that exist in the product are assured of being acted upon and separated by the dynamic forces which exist in the vortex region. These forces include not only those of a centrifugal and centripetal nature but also turning and shifting forces as the chips C frictionally engage the sides of the funnel 12 and the package T.

Adding to the effectiveness of the above dynamic forces for more complete product agitation during the stirring operation is the limited flexibility of the rod 20 which permits small radial movements of the rod 20 with respect to the center line 30 of the rotary path. In accordance with the the rod 20 is preferably made of stainless steel, giving the desired limited flexure to the length of the rod 20 that allows the action described as well as giving the required corrosive resistant property necessary for operation on the food products contemplated. This slight flexure is also of assistance in preventing chips C from being broken when a conflict of forces occurs in the vortex since the slight flexure will absorb the shock and allow the chips C to pass without damage. While only the single rod 20 is illustrated as making up the stirrer S, it ispossible to utilize two or more rods dependent upon the size and nature of the chips 30 and the amount of stirring action desired.

Another advantageous feature of the present invention is the positioning of the feeding chute 11 so as to present the chips C tangentially with respect to the rotary path of the rod 20, as clearly shown in FIG. 2 of the drawings. As will be realized, the entrance of the chips C into the flow pattern along the tangent causes a smooth merger, and as a result, opposite or conflicting forces tending to cause the fragile chips to break at this point are avoided. Furthermore, the smooth merger of the flow of chips C into the vortex pattern is assured by regulating the speed of the motor M so that the rod 20 is maintained at substantially the same speedrl n other words, as the chips C enter the vortex they are traveling at the same speed so that no differential forces will act upon the chips that could result in the breaking of the same.

As clearly shown in FIGS. 1 and 2, forward wall 40 of the funnel 12 is in juxtaposition with the rotary path of the rod 20 at a point substantially 90 around the rotary path from the point of merger. Thus, the wall 40 serves to initially guide the product toward a tight spiraling movement so that the bulk of the chips C are positioned in the path of the rod 20. By the time the chips C have traveled in an additional 90 arc or 180 from the point of merger, said chips C have begun to enter the mouth 13 of package T. Because of the triangular orientation of the system as described above, sloping rear wall 45 (note FIG. 2) of the package T falls away quickly from the rotary path from this point and the chips C are free to enter said package in an unobstructed fashion.

In summary, a product filling system 10 is provided which is continuously operable to maintain a smooth and constant flow of product by gravity into the mouth of an open package. This is accomplished by causing a whirlpool action by use of a stirrer S in the mouth 13 of the package T, which by its nature causes the chips C to fit themselves into the proper orientation to enter without a jam-up and without breakage. The. effectiveness of. this whirlpool action is maximized by depositing the chips C along the tangent of the vortex and operating the rod at the same linear speed as obtained by the chips leaving the chute 11. Other features described include the positioning of the tip of the operative end 20a of the rod 20 for best effectiveness and shaping the rod 20 so as to sweep the full area encompassed by the rotary path. Dislodgement of any lumps or clogs of the product is assured by the chips C passing through the vortex in a Z-shaped path and by allowing limited flexure of the rod 20 for radial movement with respect to the centerline 30 of said path.

In this disclosure, there is shown and described only the preferred embodiment of the invention, but, as aforementioned, it is to be understood that the invention is capable of various changes or modifications within the scope of the inventive concept as expressed by the accompanying claims.

lclaim:

1. la a dynamic product filling system for a tubular package including means for presenting said package so as to have an upwardly extending mouth to receive said product, the improvement comprising chute means for delivering said product to the mouth of said package, product stirring 87 rod means moving in a rotary path to impart a positive whirlpool action to said product entering said mouth, and means for imparting movement to said product along said chute means in substantially the same direction as movement of the rod means in said rotary path at the point of entry of said product to said path, whereby spiraling of said product down said package is induced and jam-ups prevented.

2. The combination of claim I wherein said stirring rod means comprises an arcuately shaped rod, the operative end of said rod extending down into said package, and a motor attached to the other end of said rod for rotating said rod to move the same in said rotary path.

3. The combination of claim 2 wherein the free tip of said operative end of said rod is positioned substantially along the center line of the rotary path of said rod so as to allow sweeping of said product across the full expanse of saidpath.

4. The combination of claim 3 wherein said free tip IS located substantially along the center line of said package to allow maximum space around the periphery of said package for the spiraling product moving outwardly due to centrifugal force.

5. The combination of claim 2 wherein said rod is flexible along its length to allow limited flexure with respect to said rotary path so as to increase product agitation.

6. The combination of claim 1 wherein said package, chute means and stirring rod means form a triangular intersection at said mouth so that said product follows a tortuous path during the stirring operation to encourage separation of product lumps.

' 7. The combination of claim 1 wherein said means for imparting movement includes an incline of said chute means. said inclined chute being positioned eccentrically with respect to said package so that said product merges tangentially of said rotary path whereby said whirlpool action is enhanced and breakage of said product prevented.

8. The combination of claim 7 wherein is further provided a funnel between said chute and said package to direct the product to said mouth, said stirring means extending into juxtaposition with said funnel at substantially around said rotary path from the point of merger whereby said product is confined for tight spiraling movement into said mouth.

9. The combination of claim 8 wherein said stirring rod means is spaced from said funnel around the remainder of said rotary path.

10. The method of dynamic filling a tubular package through an upwardly extending moutlh comprising the steps of presenting a flowing supply of said product, moving an elongated stirring rod in a rotary path for imparting a positive whirlpool action to said product entering said mouth, and imparting movements to said supply prior to entering said rotary path in substantially the same direction as movement of the stirring rod in said rotary path at the point of entry of said product, whereby spiraling of said product is induced and jamups prevented.

y 11. The method of claim 10 wherein the tangential speed of said rod is maintained at substantially the same speed as the supply of said product whereby breakage of said product is prevented. t

12. The method of claim l0 wherein said supply is presented tangentially to said rotary path to enhance said whirlpool action and breakage of said product is prevented.

13. The method of claim 10 wherein the movement of said stirring rod is maintained in the mouth of said package and the free tip of the operative end of said rod is held on the centerline of said package to allow maximum space around the periphery of said package for the spiraling product moving outwardly by centrifugal force. 

1. In a dynamic product filling system for a tubular package including means for presenting said package so as to have an upwardly extending mouth to receive said product, the improvement comprising chute means for delivering said product to the mouth of said package, product stirring 87 rod means moving in a rotary path to impart a positive whirlpool action to said product entering said mouth, and means for imparting movement to said product along said chute means in substantially the same direction as movement of the rod means in said rotary path at the point of entry of said product to said path, whereby spiraling of said product down said package is induced and jam-ups prevented.
 2. The combination of claim 1 wherein said stirring rod means comprises an arcuately shaped rod, the operative end of said rod extending down into said package, and a motor attached to the other end of said rod for rotating said rod to move the same in said rotary path.
 3. The combination of claim 2 wherein the free tip of said operative end of said rod is positioned substantially along the center line of the rotary path of said rod so as to allow sweeping of said product across the full expanse of said path.
 4. The combination of claim 3 wherein said free tip is located substantially along the center line of said package to allow maximum space around the periphery of said package for the spiraling product moving outwardly due to centrifugal force.
 5. The combination of claim 2 wherein said rod is flexible along its length to allow limited flexure with respect to said rotary path so as to increase product agitation.
 6. The combination of claim 1 wherein said package, chute means and stirring rod means form a triangular intersection at said mouth so that said product follows a tortuous path during the stirring operation to encourage separation of product lumps.
 7. The combination of claim 1 wherein said means for imparting movement includes an incline of said chute means, said inclined chute being positioned eccentrically with respect to said package so that said product merges tangentially of said rotary path whereby said whirlpool action is enhanced and breakage of said product prevented.
 8. The combination of claim 7 wherein is further provided a funnel between said chUte and said package to direct the product to said mouth, said stirring means extending into juxtaposition with said funnel at substantially 90* around said rotary path from the point of merger whereby said product is confined for tight spiraling movement into said mouth.
 9. The combination of claim 8 wherein said stirring rod means is spaced from said funnel around the remainder of said rotary path.
 10. The method of dynamic filling a tubular package through an upwardly extending mouth comprising the steps of presenting a flowing supply of said product, moving an elongated stirring rod in a rotary path for imparting a positive whirlpool action to said product entering said mouth, and imparting movements to said supply prior to entering said rotary path in substantially the same direction as movement of the stirring rod in said rotary path at the point of entry of said product, whereby spiraling of said product is induced and jam-ups prevented.
 11. The method of claim 10 wherein the tangential speed of said rod is maintained at substantially the same speed as the supply of said product whereby breakage of said product is prevented.
 12. The method of claim 10 wherein said supply is presented tangentially to said rotary path to enhance said whirlpool action and breakage of said product is prevented.
 13. The method of claim 10 wherein the movement of said stirring rod is maintained in the mouth of said package and the free tip of the operative end of said rod is held on the centerline of said package to allow maximum space around the periphery of said package for the spiraling product moving outwardly by centrifugal force. 